Step 22: The Rest of the Costume

Step 23: Putting it all Together

The final assembly!Bolt it all together, just like I'm sure you did a few times before it was painted, put on the costume, and have a nerdy good time....

What self respecting nerd wouldn't want to be a character out of Team Fortress 2 for Halloween? There are plenty of options, but given my physique (or lack thereof) I decided I'd try my hand at the Heavy.

The costume itself is fairly straight forward, but to be convincing it requires two things that aren't likely to be ready at hand: a mini-gun and a bandoleer of extremely large bullets. A simple google search will turn up plenty of other people's attempts at the same thing, but they all seem to lack something... craftsmanship!

Seeing that I decided, as any good instructables junkie would, to make the best effort possible and document the process for anyone else who wanted to do the same.

All together the costume will probably cost about $75, assuming you have all the tools but none of the parts, and take about 20-25 hours to assemble. Time consuming, sure, but totally worth it.

The first step, before even looking for materials, was to spend an hour or so looking at all the best source images I could find and sketching out my design. Even if you plan to follow my design to the letter I'd recommend doing something similar, I find it helps immensely to have a really good mental picture of the problem at hand before starting.

Your costume is flawless, except that you don't have a sandvich (bet you are TIRED of hearing that).So here's another idea: replicate the new eatable-The Dalokah's Bar-by buying a hershey's bar. Simpler, more effective, and moar delicious. :3

Why would it be a propane tank? The thing attached to the pyro's flamethrower is obviously a propane tank and that makes sense, but since this has a chute on it that spits spent cartridges and is attached to a giant gun instead of a flamethrower it would make sense that it's where the ammo is held, don't you think?